Swinging gate containers

ABSTRACT

A collapsible container having thick corrugated outer walls with two generally U-shaped inserts provided within the corrugated walls. The inserts are reversed and offset from one another with one panel of each insert being secured to an interior panel of the collapsible container. Having two of the three panels of each insert unsecured to the interior panels allows the collapsible container to be more easily collapsed for storage and transport.

TECHNICAL FIELD

The disclosed embodiments relate generally to bulk containers for flowable materials, and in particular, to bulk containers having improved sidewalls.

BACKGROUND OF THE INVENTION

Cylindrical containers, such as drums, do not maximize floor and pallet space for storage and transport. It would be desirable to provide a container in a rectangular shape to maximize storage of material on the footprint of a standard pallet.

Conventional rigid containers, such as drums, for the storage and transportation of flowable or fluid materials are bulky and heavy even when not in use. It would therefore be desirable to provide a lightweight container constructed of cardboard or the like. One drawback associated with the use of cardboard is the tendency of cardboard to deform from a rectangular cross section toward a circular cross section.

It is known to provide reinforcements to prevent such deformation but reinforcements can be complex heavy and expensive. It is also known to provide the container with additional layers of cardboard to increase the strength of the container. One drawback associated with cardboard containers having increased layers is the difficulty associated with bending the increased thickness of the corner into a stable corner. The additional thickness of the material prevents the formation of a sharp corner, causing the material to bias the corner toward a more rounded corner. It is also known to remove material in a generally v-shape to facilitate the bending of the material to create a corner. One drawback associated with removing material is the weakness of the resulting corner associated with the reduction of material.

Another drawback associated with the removing material is the additional time and expense associated with the extra step of removing the material.

Yet another drawback associated with removal of material to form a corner is the precision required to provide the desired corner without removing too much material and leaving the corner subject to failure.

It is also known in the art to crease the material to form a corner. While such a crease may work for cardboard structures having a thinner sidewall, for thicker containers having three or more layers of corrugation, it is often difficult to provide a crease sufficient to create a corner that does not bias toward an open, rounded, and weaker orientation. It would therefore be desirable to provide a lightweight, flexible container having increased wall thickness with a corner that is strong and resists bias toward an open configuration.

SUMMARY OF THE DISCLOSED SUBJECT MATTER

The present invention includes a collapsible container having an outer container and two U-shaped inserts. The outer container has four outer walls while the first and second inserts have three walls each. One wall of each of the inserts is secured to the interior of the outer container while the remaining two walls are opened outward into contact with the interior of the outer container. The features and advantages described in the summary and the following detailed description are not all-inclusive. Many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims presented herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described, by way of example, with reference to the accompanying drawings in which:

FIG. 1 illustrates a side perspective elevation in accordance with one embodiment;

FIG. 2 illustrates a top elevation of the outer container of the container of FIG. 1;

FIG. 3 illustrates a top elevation of the two inserts of the container of FIG. 1;

FIG. 4 illustrates a top elevation of the two inserts placed within the outer container but not fully expanded into contact with the inner walls of the outer container of FIG. 1;

FIG. 5 illustrates a top elevation of the two inserts placed within the outer container and expanded into contact with the interior walls of the outer container of the container of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

A collapsible container for containing flowable materials is shown generally as (10) in FIG. 1. As shown, the container (10) includes an outer container (12), having a bottom (14) and a pair of U-shaped inserts (16 & 18). The outer container (12) is preferably provided with four panels including a first outer panel (20), a second outer panel (22), a third outer panel (24), and fourth outer panel (26). If desired, the outer container (12) may be hexagonal, octagonal, or of any desired configuration, having any desired number of panels. (FIGS. 1-2). As shown in FIG. 3, the first insert (16) is provided with a first inner panel (28), a second inner panel (30), and a third inner panel (32). Similarly the second insert (18) is provided with a fourth inner panel (34), a fifth inner panel (36), and a sixth inner panel (38). While the outer container (12), bottom (14) and inserts (16 &18) may be constructed of any desired material, in the preferred embodiment; they are constructed of corrugated cardboard such as that known in the art. Preferably, the outer container (12) and bottom (14) are constructed of triple corrugated cardboard while the inserts (16 & 18) are constructed of double corrugated cardboard.

As shown in FIG. 2, the outer container (12) is constructed of two long sheets (40 & 42) of triple corrugated cardboard. The first sheet (40) extends the entire perimeter of the outer container (12) and includes and extra securement tab (44) which allows the first sheet (40) to be glued to itself using an adhesive in a manner such as that known in the art. The second sheet (42) abuts the first sheet (40), extends across the interior of the first sheet (40), and is provided with a securement tab (46) to allow the second sheet (42) to be secured to both itself and the first sheet (40) by adhesive in a manner such as that known in the art. Preferably the securement tab (46) extends across the gap (48) formed between the sheets (40 & 42) to reduce any weakness associated with the gap (48)

As shown in FIG. 3, the inserts (16 & 18) are inverted and off-set from one another. This locates the sixth panel (38) on the interior of the first insert (16) and the third inner panel (32) on the interior of the second insert (18).

To construct the collapsible container (10), the sheets (40 & 42) are creased in a manner such as that known in the art and adhesively secured to one another with the adhesive being applied in the interstice between the sheets (40 & 42) in a manner such as that known in the art. Thereafter, the third inner panel (32) of the first insert (16) is folded inward and the first insert (16) is provided within the outer container (12) in a manner such as that shown in FIG. 4. Similarly, the sixth inner panel (38) is folded inward and the second insert (18) is inserted within the outer container (12). Preferably the third inner panel (32) is pivotably coupled to the second inner panel (30) in a manner that allows the third inner panel (32) to pivot between a first position angled about 45 degrees relative to the second panel (22) and a second position angled about 90 degrees relative to the second panel (22). The third inner panel (32) may be pivotably coupled to the second inner panel (30) in a manner that allows the third inner panel (32) to rotate from a position wherein most of one side of the third inner panel (32) is in contact with most of one side of the second inner panel (30) to a position wherein most of the opposite side of the third inner panel (32) is in contact with the fourth inner panel (34) If the outer container (12) is provided with more than four panels, the third inner panel (32) may be pivotably coupled to the second inner panel (30) in a manner that allows the third inner panel (32) to pivot more than 90 degrees relative to the second inner panel (30).

Once the inserts (16 & 18) have been provided within the outer container (12) in a manner such as that shown in FIG. 4, the first inner panel (28) is secured to the first panel (20) by an adhesive in a manner such as that known in the art. Similarly, the fourth inner panel (34) is secured to the third panel (24) by an adhesive in a manner such as that known in the art. While the second inner panel (30) and fourth inner panel (34) may also be adhesively secured to the outer container (12), in the preferred embodiment, the second inner panel (30) and fourth inner panel (34) are not adhesively secured to the outer container (12). Similarly, neither the third inner panel (32) nor the sixth inner panel (38) are adhesively secured to the outer container (12). Once the first inner panel (28) and fourth inner panel (34) have been adhesively secured to the outer container (12), the third inner panel (32) is extended relative to the second inner panel (30) until most of the exterior side (52) of the third inner panel (32) is in contact with most of an interior side (54) of the fourth inner panel (34). Similarly, the sixth inner panel (38) is rotated relative to the fifth inner panel (36) until most of an exterior side (56) of the sixth inner panel (38) is in contact with most of an interior side (58) of the first inner panel (28).

The inner panels (28-38) are preferably about the same dimensions. The third inner panel (32) has at least 50%, more preferably at least 75%, and most preferably at least 85% the surface area of the fourth inner panel (34). Similarly, the fourth inner panel (34) has at least 50%, more preferably at least 75%, and most preferably at least 85% the surface area of the third inner panel (32). Once the inserts (16 & 18) have been positioned within the outer container (12), as shown in FIG. 5, the collapsible container (10) defines a large interior space (60).

As shown in FIG. 1 a flexible liner (62) is provided in the space (60). The flexible liner (62) is preferably constructed of polyethylene, such as that known in the art, to hold non-hazardous flowable material (64). The liner (62) is provided with a nozzle (66) that extends through a circular cutout (68) provided in the collapsible container (10). The circular cutout (68) extends through the fourth panel (26) and the fifth inner panel (36) to provide access to the flowable material (64) from outside of the collapsible container (10). The nozzle (66) is provided with a collar (70) in a manner, such as that known in the art to prevent the nozzle (66) and the collar (70) from passing through the cutout (68).

The liner (62) is also provided with a top cap (72). The opening (74) in the top of the collapsible container (10) allows a large fuel head (not shown) to enter the collapsible container (10) coupled to the top cap (72) and fill the liner (62) with flowable materials (64). As the liner (62) fills with flowable materials (64), such as fruit juice concentrate, tomato paste, or the like, hydrostatic pressure forces the liner (62) against the second inner panel (30), the third inner panel (32), the fifth inner panel (36) and the sixth inner panel (38) and downward against the bottom (14). This hydrostatic pressure presses firmly against the panels preventing the second inner panel (30) and the fifth inner panel (36) from becoming dislodged from the outer container (12), the third inner panel (32) from becoming dislodged from the fourth inner panel (34), and the sixth inner panel (38) from becoming dislodged from the first inner panel (28). The more flowable material (64) added to the liner (62), the greater pressure on the panels and the less likely that the panels will become dislodged.

While the top (76) of the collapsible container (10) may be bowed slightly outward once the liner (62) has been filled with flowable material (64), the additional reinforcement of the inserts (16 & 18) prevent the panels (20-26) from bowing outward into a circular orientation. As shown in FIG. 1 once the liner (62) has been filled with flowable materials (64), the top cap (72) is closed and a lid (78) is provided over the top (76) of the collapsible container (10). Although the lid (78) may be of any desired construction, in the preferred embodiment, the lid (78) is a piece of double corrugated cardboard provided with side panels (80) angled downward to cover a portion of the panels (20-26). Once the lid (78) has been applied, the side outer container (12) of the lid (78) may be adhesively secured to the panels (20-26) or, more preferably secured with adhesive tape. If desired, the container (10) may be wrapped with film (not shown) in a manner such as that known in the art.

The lid (78) may be provided with any size opening to allow access to the top cap (72) by the fill head or any desired apparatus, even after the lid (76) has been secured over the collapsible container (10). Although the outer container (12) may be of any suitable dimensions, in the preferred embodiment, the bottom (14) is dimensioned to fit on a standard 48-inch long and 40-inch wide stringer pallet (82). If desired, the bottom (14) of the collapsible container (10) may be secured to the pallet (82) by hydrostatic force and/or the bottom (14) may be adhesively or otherwise secured to the pallet (82).

By providing the inserts (16 & 18) within the outer container (12) and adhesively securing the first inner panel (28) and fourth inner panel (34) to the outer container (12), the collapsible container (10) obtains the benefit of increased sidewall thickness while reducing the problems associated with folding panels of a similar thickness adhesively secured to one another. This allows the corners (84, 86, 88 and 90) to bend into the desired configuration of the collapsible container (10) more readily, without having to be provided with costly corner cutouts or the like.

Although the invention has been described with respect to a preferred embodiment thereof, it is to be understood that it is not to be so limited since changes and modifications can be made therein which are within the full, intended scope of this invention as defined by the appended claims. 

1. A collapsible container comprising: a. an outer container comprising; i. a first outer panel; ii. a second outer panel coupled to the first outer panel; iii. a third outer panel coupled to the second outer panel; iv. a fourth outer panel coupled to the third outer panel; b. a first insert comprising: i. a first inner panel; ii. a second inner panel coupled to the first inner panel; iii. a third inner panel coupled to the second inner panel; c. a second insert comprising: i. a fourth inner panel; ii. a fifth inner panel coupled to the fourth inner panel; iii. a sixth inner panel coupled to the fifth inner panel; d. wherein the first inner panel is positioned between the outer container and the sixth inner panel; and e. wherein the fourth inner panel is positioned between the outer container and the third inner panel.
 2. The collapsible container of claim 1, wherein the first inner panel is secured to the outer container.
 3. The collapsible container of claim 2, wherein the third inner panel is unsecured to the outer container.
 4. The collapsible container of claim 3, wherein the third inner panel has at least 75% the surface area of the fourth inner panel.
 5. The collapsible container of claim 4, wherein the fourth inner panel has at least 75% the surface area of the third inner panel.
 6. The collapsible container of claim 3, wherein the third inner panel is pivotable between a first position wherein the most of a side of the third inner panel is in contact with most of a side of the fourth inner panel and a second position wherein the most of the side of the third inner panel is not in contact with most of the side of the fourth inner panel.
 7. The collapsible container of claim 3, wherein the fourth inner panel is secured to the outer container.
 8. The collapsible container of claim 7, wherein the sixth inner panel is unsecured to the outer container.
 9. The collapsible container of claim 1, wherein the first inner panel is adhesively secured to the first outer panel.
 10. The collapsible container of claim 9, wherein the third inner panel is unsecured to the outer container.
 11. The collapsible container of claim 10, wherein the fourth inner panel is adhesively secured to the third outer panel.
 12. The collapsible container of claim 1, wherein the third inner panel is pivotable between a first position angled about forty-five degrees relative to the second inner panel and a second position angled about ninety degrees relative the second inner panel.
 13. The collapsible container of claim 12, wherein the first inner panel is secured to the outer container.
 14. The collapsible container of claim 13, wherein the third inner panel is unsecured to the outer container.
 15. The collapsible container of claim 12, wherein the sixth inner panel is pivotable between a third position angled about forty-five degrees relative to the fifth inner panel and a second position angled about ninety degrees relative the fifth inner panel.
 16. A collapsible container comprising: a. an outer container comprising; i. a first outer panel; ii. a second outer panel coupled to the first outer panel; iii. a third outer panel coupled to the second outer panel; iv. a fourth outer panel coupled to the third outer panel; b. a first insert comprising: i. a first inner panel secured to the outer container; ii. a second inner panel coupled to the first inner panel; iii. a third inner panel coupled to the second inner panel unsecured to the outer container; c. a second insert comprising: i. a fourth inner panel; ii. a fifth inner panel coupled to the fourth inner panel; iii. a sixth inner panel coupled to the fifth inner panel; d. wherein the first inner panel is positioned between the outer container and the sixth inner panel; e. wherein the fourth inner panel is positioned between the outer container and the third inner panel; and f. wherein the third inner panel is pivotable between a first position wherein the most of a side of the third inner panel is in contact with most of a side of the fourth inner panel and a second position wherein the most of the side of the third inner panel is not in contact with most of the side of the fourth inner panel.
 17. The collapsible container of claim 16, wherein the third inner panel has at least 75% the surface area of the fourth inner panel.
 18. The collapsible container of claim 17, wherein the fourth inner panel has at least 75% the surface area of the third inner panel.
 19. A collapsible container comprising: a. An outer container comprising; i. A first outer panel; ii. A second outer panel coupled to the first outer panel; iii. A third outer panel coupled to the second outer panel; iv. A fourth outer panel coupled to the first outer panel and the third outer panel; b. A first insert comprising: i. A first inner panel secured to the outer container; ii. A second inner panel coupled to the first inner panel; iii. A third inner panel coupled to the second inner panel unsecured to the outer container; c. A second insert comprising: i. A fourth inner panel; ii. A fifth inner panel coupled to the fourth inner panel; iii. A sixth inner panel coupled to the fifth inner panel; d. Wherein the first inner panel is positioned between the outer container and the sixth inner panel; e. Wherein the fourth inner panel is positioned between the outer container and the third inner panel; and f. Wherein the third inner panel is pivotable in and out of substantial contact with the fourth inner panel.
 20. The collapsible container of claim 19, wherein the sixth inner panel is pivotable in and out of substantial contact with the first inner panel. 